Johnson 115 lower unit disassembly problem

[grw5]

I have a 1978 Johnson 115 that I am trying to disassemble the lower unit on. I got it from an aquaintance that had been setting up for several years. When last used it would not go into reverse. I drained the oil and there was a large amount of water, (but no metal shavings) so I imagine the shift mechanism must be corroded. I pulled the lower unit off and began trying to disasseble it per the repair manual. I am not able to get the prop shaft bearing carrier out. I have removed the four bolts that hold it on, I have tried a puller to it, and applied heat to the outside of the housing with a propane torch. Since the typical steering wheel type puller wants to bend over when you apply a high load to the prop shaft, I have rigged up a plate to pull on the bearing carrier against the housing. I have tightened the 5/16" bolts to the point where I am afraid they will twist off. It still doesn't budge, even with penetrating fluid, and with tapping on it with a hammer. My next step is to use a hotter torch. Do any of you "seasoned" mechanics have any more suggestions? I really appreciate your advice.

 

[wilde1j]

Re: Johnson 115 lower unit disassembly problem

You may have to make a heavy duty puller with pieces that grab under two of the four webs at the end of the bearing carrier. If the motor has seen saltwater, the bearing carrier may come out VERY HARD. I have a puller I made up for that very job, using a trailer draw bar, drilled and tapped for for the main puller center bolt. I used 1/2" all thread for the pieces that extend into the bearing carrier and made lugs from the draw bar (5/8" steel), drilled and tapped for 1/2" and used 1/2" nuts top and bottom to lock the lugs in place. I screwed that sucker as tight as I could, then applied lots of heat with a propane torch. Eventually, the carrier will start to move. Takes lots of force and patience!

Any standard puller I tried wasn't up to the job most of the time. If you're interested, send me your email address and I'll try to find the puller and send you a picture of it. It's really a brute.

 

[F_R]

Re: Johnson 115 lower unit disassembly problem

I've had to destroy some of them to get them out after being used in salt water. Drill holes through the outer rim of the "spool" and knock sections of it out. The remainder then can flex inward, easing it's grip on the gearcase. Carriers are cheaper than gearcases.

 

[grw5]

Re: Johnson 115 lower unit disassembly problem

I made a puller very similar to what wilde1j suggested. It worked, but it broke out one of the sections of the outer rim, as F_R suggested doing, before it came loose. I fortunately found a replacement bearing carrier on ebay that looks like it should work. I had to get the right snap ring pliers to go deeper into it. What a can of worms! Thanks for your help!